Manifold header for use at a wellsite

ABSTRACT

A pumping system for pumping a fluid for a wellsite. The pumping system includes a manifold assembly and pumping systems in fluid communication with the manifold header. The manifold assembly includes a manifold header that includes a manifold header body and outlets. The manifold header body includes an inlet to receive the fluid and an interior bore. Each outlet includes an entrance section shaped to have a profile that is approximately the same as a profile of an inner surface of the manifold header body, an outlet port shaped to flow the fluid approximately perpendicular to a longitudinal axis of the manifold header body, and a transition section shaped to have a radius of curvature that transitions from the profile of the entrance section to the outlet port and reduces internal erosion of the outlet due to the fluid flowing from the manifold header and through the outlet port.

BACKGROUND

This section is intended to provide relevant background information tofacilitate a better understanding of the various aspects of thedescribed embodiments. Accordingly, it should be understood that thesestatements are to be read in this light and not as admissions of priorart.

Manifolds are frequently used in hydraulic fracturing systems to directthe flow of fracturing fluid. Conventional manifolds with welded-onoutlets tend to wear prematurely. The piping within the manifold mustredirect the viscous fracturing fluid at high contact angles and highpressure, resulting in turbulent flow and subjecting the manifold toerosive wear. The piping within the manifold is particularly eroded atjunctions where the direction of fluid flow changes sharply, such as atthe joint between the outlet and the manifold header body and at thespool where the flange is welded onto the outlet.

Erosive wear on the outlets causes washout, leading to pipe leaks andpotentially failure. Premature wear increases equipment maintenance andreplacement costs. Reinforcing plates can be added at the joints,spools, and other pipe locations most affected by wear, but such platesare costly and difficult to install due to their weight and intricatepositioning within the manifold header. The joint connection can besanded for a smoother joint resulting in slower wear, but the manifoldsstill incur premature wear. A need therefore exists for a manifoldheader capable of redirecting fluid flow through the outlets withoutcausing such premature wear.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of a manifold header are described with reference to thefollowing figures. The same numbers are used throughout the figures toreference like features and components. The features depicted in thefigures are not necessarily shown to scale. Certain features of theembodiments may be shown exaggerated in scale or in somewhat schematicform, and some details of elements may not be shown in the interest ofclarity and conciseness.

FIG. 1 is a schematic view of a wellsite according to one or moreembodiments;

FIG. 2 is an isometric view of a manifold header, according to one ormore embodiments;

FIG. 3 is a manifold assembly that includes the manifold header of FIG.2, according to one or more embodiments;

FIG. 4 is a cross-sectional view of the manifold header of FIG. 2 alongline AA;

FIG. 5A is an isometric view of the outlet of FIG. 2; and

FIG. 5B is an internal view of the outlet of FIG. 2.

DETAILED DESCRIPTION

The present disclosure describes a manifold header. The manifold headerincludes an inlet and multiple holes that each have an outlet disposedtherein. Fracturing fluid, well treatment fluid, or other wellsitefluids are received in the inlet and distributed to pumping systems orother wellsite equipment via the outlets. The interior profile of theoutlets reduces internal erosion of the outlet, allowing for a longerservice life of the manifold header. Additionally, the manifold headercan be used as a suction manifold that receives fluid from multiplesources and discharges the combined fluid through a single port.

FIG. 1 is a schematic diagram of a wellsite 100, according to one ormore embodiments. Turning to FIG. 1, the wellsite includes a wellhead102 positioned over a wellbore (not shown) and connected to one or morepieces of wellsite equipment, such as, pumping systems 104. The pumpingsystems 104 are connected to a manifold assembly 106 and piping 108.Further, the piping 108 may include additional equipment, such as,valves 110 and flowmeters (not shown). This additional equipment may beused, e.g., to monitor and/or control the flow of fluid into a wellborethrough the wellhead 102.

The wellsite 100 may also include other pieces of equipment, such as, agenerator 112, a blender 114, storage tanks 116 (two shown), adistribution manifold header 118, and a monitoring and control unit 120.Each of these additional pieces of equipment is described below.

The storage tanks 116 may contain fuel, wellbore fluids, proppants,diesel exhaust fluid, and/or other fluids. The distribution manifoldheader 118 is fluidly coupled to one or more pieces of wellsiteequipment, such as, the pumping systems 104, the generator 112, theblender 114, or the monitoring and control unit 120. The distributionmanifold header 118 may distribute fluids, such as, fuel, diesel exhaustfluid, fracturing fluid, and/or other fluids, to the pieces of wellsiteequipment 104, 112, 114 from one or more of the storage tanks 116 and/orthe blender 114. In one or more embodiments, all or a portion of theaforementioned wellsite equipment may be mounted on trailers. However,the wellsite equipment may also be free standing or mounted on a skid.

Turning now to FIG. 2, FIG. 2 is an isometric view of a distributionmanifold header 218, according to one or more embodiments. Thedistribution manifold header 218 includes a manifold header body 200having an interior bore 202, two inlets 204, and outlets (one indicated,206). In other embodiments, one of the inlets 204 may be omitted and theinterior bore 202 may extend through only a portion of the manifoldheader body 200. The distribution manifold header 218 may also includemounting brackets, such as the mounting bracket 208 shown in FIG. 2. Inother embodiments, the mounting bracket 208 may be omitted or positionedin different locations based on the mounting configuration of thedistribution manifold header 218.

As shown in the illustrated embodiment, the inlets 204 may each includea flange 210 that is welded to or formed from the manifold header body200. A mating flange coupled to a supply pipe or hose (not shown) may bebolted to one of the flanges 210 to supply fluid to the distributionmanifold header 218. In other embodiments, a supply pipe or hose may becoupled to the distribution manifold header 218 via a threadedconnection, welded connection, or other type of connection know to thoseskilled in the art. Further, one of the inlets 204 may not be used inall applications. In such applications, the inlet 204 not in use besealed via a blank flange or similar component (not shown).

The outlets 206 may be welded to the manifold header body 200. In otherembodiments, the outlets may be integrally formed with the manifoldheader body 200 via machining, additive manufacturing, or other meansknown to those skilled in the art. In one or more embodiments, thedistribution manifold header 218 includes outlets 206 that may bepositioned across the entire circumference of the distribution manifoldheader 218, instead of only a portion of the circumference as shown inFIG. 2. Additionally, the outlets 206 may vary in size from one another(e.g., one outlet 206 may be sized for a 4 inch flange connection andthe remaining outlets 206 may be sized for a 6 inch flange connection),with each outlet 206 maintaining the internal profile discussed in moredetail below.

Each outlet includes a flange connection 212 on the exterior surfacethat can be bolted to a mating flange (one indicated, 300) that iscoupled to a valve (one indicated, 302), as shown in FIG. 3. The valve302, in turn, may be coupled to a pipe or hose (not shown) thattransports the fluid from the distribution manifold header 218 to thepiece of equipment, such as a pumping system 104 shown in FIG. 1, whichutilizes the fluid. In other embodiments, the valve 302 may be omittedand the outlet 206 may be coupled to a flange (not shown) that iscoupled to a pipe or hose. A blank flange or similar component (notshown) may also be bolted to an outlet 206 to seal an outlet 206 that isnot in use.

In use, a fluid, e.g., fracturing fluid, may be received by thedistribution manifold header 218 via a pumping system (not shown) in ablender, such as the blinder 114 shown in FIG. 1. The fracturing fluidis distributed via the outlets 206 of the distribution manifold header218 to each of multiple pumping systems, such as pumping systems 104shown in FIG. 1. The pumping systems then pressurize the fluid and pumpthe fluid into the wellbore via a wellhead, such as the wellhead 102shown in FIG. 1.

Although the manifold header 218 is described above as a distributionmanifold header, the manifold header 218 is not thereby limited. Themanifold header may also be used as a suction manifold. In suchinstances, the outlets 206 are instead used to receive fluid fromvarious sources and the combined fluid is discharged from the inlet 204.

Turning now to FIGS. 4, 5A, and 5B, FIG. 4 is a cross-section of thedistribution manifold header 218 of FIG. 2 along line AA and FIGS. 5Aand 5B are isometric and internal views of an outlet 206, respectively.As shown in FIG. 4, portions of the manifold header body 200 are removedto create holes that receive outlets 206. The outlets 206 are thenwelded to the manifold header body 200 to form the distribution manifoldheader 218. In other embodiments, the outlets may be formed from themanifold header body 200 by machining, additive manufacturing, or othermeans known to those skilled in the art.

Each outlet includes an entrance section 400, a transition section 402,and an outlet port 404. As shown most clearly in FIG. 4, the entrancesection 400 is shaped to have approximately the same profile as theinner surface 406 of the surrounding manifold header body 200. As shownmost clearly in FIG. 5A, outlet, which is a cylinder having straightwalls such that the fluid flow through the outlet port 404 isapproximately perpendicular to a longitudinal axis of the manifoldheader body 200. the transition section 402 has a radius of curvaturethat transitions between the entrance section 400 and the outlet port404 The surface area of the transition section 402 between the entrancesection 400 and the outlet port 404 may not be uniform about thecircumference of the outlet port 404 due to the position of the outletport 404 relative to the manifold header body 200, as well as the sizeof the outlet port 404, as shown in FIGS. 4 and 5A. Additionally,although the transition section 402 is depicted in FIG. 5B is an oval,other embodiments may include a circular transition section 402.

By flowing fluid across the radius of curvature of the transitionssection 402, instead of a sharp corner that would be created if the portwas formed through the entrance section 400, less turbulence isintroduced into the fluid flowing therethrough. This reduction inturbulence reduces the internal erosion of the outlet 206 as fluid isflowing from the interior bore 202 of the manifold header body 200 andthrough the outlet port 404, when compared to the previously describedsharp corner.

Further examples include:

Example 1 is a pumping system for pumping a fluid for a wellsite. Thepumping system includes a manifold assembly and a plurality of pumpingsystems, each pumping system in fluid communication with a respectiveoutlet of the manifold header. The manifold assembly includes a manifoldheader. The manifold header includes a manifold header body and aplurality of outlets. The manifold header body includes an inlet toreceive the fluid and an interior bore. Each outlet includes an entrancesection shaped to have a profile that is approximately the same as aprofile of an inner surface of the manifold header body, an outlet portshaped to flow the fluid approximately perpendicular to a longitudinalaxis of the manifold header body, and a transition section shaped tohave a radius of curvature that transitions from the profile of theentrance section to the outlet port and reduces internal erosion of theoutlet due to the fluid flowing from the manifold header and through theoutlet port.

In Example 2, the embodiments of any preceding paragraph or combinationthereof further include wherein the manifold header body furthercomprises holes formed along a length of the manifold header body andeach outlet is coupled to the manifold header body at a respective hole.

In Example 3, the embodiments of any preceding paragraph or combinationthereof further include wherein the outlets are integrally formed withthe manifold header body.

In Example 4, the embodiments of any preceding paragraph or combinationthereof further include wherein a surface area of the transition sectionbetween the entrance section and the outlet port is not uniform about acircumference of the outlet port.

In Example 5, the embodiments of any preceding paragraph or combinationthereof further include wherein a first outlet of the plurality ofoutlets is a different size than a second outlet of the plurality ofoutlets.

In Example 6, the embodiments of any preceding paragraph or combinationthereof further include wherein the manifold assembly further comprisesa plurality of valves, wherein each valve is connected to a respectiveoutlet of the plurality of outlets.

In Example 7, the embodiments of any preceding paragraph or combinationthereof further include wherein each outlet further comprises a flangeconnection on an exterior surface.

In Example 8, the embodiments of any preceding paragraph or combinationthereof further include wherein the transition section is either an ovalor a circle.

Example 9 is a method of pumping fluid into a wellbore. The methodincludes flowing the fluid from at least one of a blender or a storagetank to an inlet of a manifold header. The method also includes flowingthe fluid into entrance sections of a plurality of outlets of themanifold header, each entrance section shaped to have a profile that isapproximately the same as a profile of an inner surface of a manifoldheader body. The method further includes transitioning the fluid fromthe entrance sections to respective outlet ports of the plurality ofoutlets via transition sections of the plurality of outlets, eachtransition section having a radius of curvature that transitions fromthe profile of the entrance section to the outlet port to reduceinternal erosion of the outlet due to the fluid flowing from themanifold header and through the outlet port, and each outlet port shapedto flow the fluid approximately perpendicular to a longitudinal axis ofthe manifold header body. The method also includes distributing thefluid to a plurality of pumping systems via the outlet ports. The methodfurther includes pumping the fluid into the wellbore via the pluralityof pumping systems.

In Example 10, the embodiments of any preceding paragraph or combinationthereof further include wherein distributing the fluid to the pumpingsystems includes distributing the fluid to a first pumping system of theplurality of pumping systems via a first outlet port of a first outletof the plurality of outlets. Distributing the fluid to the pumpingsystems also includes distributing the fluid to a second pumping systemof the plurality of pumping systems via a second outlet port of a secondoutlet of the plurality of outlets. The first outlet is a different sizethan the second outlet.

In Example 11, the embodiments of any preceding paragraph or combinationthereof further include wherein distributing the fluid to the pluralityof pumping systems via the outlet ports further comprises opening avalve coupled to an outlet of the plurality of outlets.

In Example 12, the embodiments of any preceding paragraph or combinationthereof further include wherein the fluid is fracturing fluid.

Example 13 is a manifold assembly that includes a manifold header. Themanifold header includes a manifold header body and a plurality ofoutlets. The manifold header body includes an inlet to receive the fluidand an interior bore. Each outlet includes an entrance section shaped tohave a profile that is approximately the same as a profile of an innersurface of the manifold header body, an outlet port shaped to flow thefluid approximately perpendicular to a longitudinal axis of the manifoldheader body, and a transition section shaped to have a radius ofcurvature that transitions from the profile of the entrance section tothe outlet port and reduces internal erosion of the outlet due to thefluid flowing through the outlet port.

In Example 14, the embodiments of any preceding paragraph or combinationthereof further include wherein the manifold header body furthercomprises holes formed along a length of the manifold header body andeach outlet is coupled to the manifold header body at a respective hole.

In Example 15, the embodiments of any preceding paragraph or combinationthereof further include wherein the outlets are integrally formed withthe manifold header body.

In Example 16, the embodiments of any preceding paragraph or combinationthereof further include wherein a surface area of the transition sectionbetween the entrance section and the outlet port is not uniform about acircumference of the outlet port.

In Example 17, the embodiments of any preceding paragraph or combinationthereof further include wherein a first outlet of the plurality ofoutlets is a different size than a second outlet of the plurality ofoutlets.

In Example 18, the embodiments of any preceding paragraph or combinationthereof further include a plurality of valves, wherein each valve isconnected to a respective outlet of the plurality of outlets.

In Example 19, the embodiments of any preceding paragraph or combinationthereof further include wherein each outlet further comprises a flangeconnection on an exterior surface.

In Example 20, the embodiments of any preceding paragraph or combinationthereof further include wherein the transition section is either an ovalor a circle.

As used herein, the term “approximately” includes all values within 10%of the target; e.g., approximately 11 inches includes all sizes from 9.9inches to 12.1 inches, including 9.9 inches & 12.1 inches.

Certain terms are used throughout the description and claims to refer toparticular features or components. As one skilled in the art willappreciate, different persons may refer to the same feature or componentby different names. This document does not intend to distinguish betweencomponents or features that differ in name but not function.

Reference throughout this specification to “one embodiment,” “anembodiment,” “an embodiment,” “embodiments,” “some embodiments,”“certain embodiments,” or similar language means that a particularfeature, structure, or characteristic described in connection with theembodiment may be included in at least one embodiment of the presentdisclosure. Thus, these phrases or similar language throughout thisspecification may, but do not necessarily, all refer to the sameembodiment.

The embodiments disclosed should not be interpreted, or otherwise used,as limiting the scope of the disclosure, including the claims. It is tobe fully recognized that the different teachings of the embodimentsdiscussed may be employed separately or in any suitable combination toproduce desired results. In addition, one skilled in the art willunderstand that the description has broad application, and thediscussion of any embodiment is meant only to be exemplary of thatembodiment, and not intended to suggest that the scope of thedisclosure, including the claims, is limited to that embodiment.

What is claimed is:
 1. A pumping system for pumping a fluid for awellsite, the system comprising: a manifold assembly comprising amanifold header comprising: a manifold header body comprising an inletto receive the fluid and an interior bore; and a plurality of outletsfrom the interior bore, each comprising: an entrance section shaped tohave a profile that is approximately the same as a profile of an innersurface of the manifold header body interior bore; an outlet port shapedto flow the fluid approximately perpendicular to a longitudinal axis ofthe manifold header body; and a transition section shaped to have aradius of curvature that transitions from the profile of the entrancesection to the outlet port and reduces internal erosion of the outletdue to the fluid flowing from the manifold header and through the outletport; and a plurality of pumping systems, each pumping system in fluidcommunication with a respective outlet of the manifold header.
 2. Thepumping system of claim 1, wherein the manifold header body furthercomprises holes formed along a length of the manifold header body andeach outlet is coupled to the manifold header body at a respective hole.3. The pumping system of claim 1, wherein the outlets are integrallyformed with the manifold header body.
 4. The pumping system of claim 1,wherein a surface area of the transition section between the entrancesection and the outlet port is not uniform about a circumference of theoutlet port.
 5. The pumping system of claim 1, wherein a first outlet ofthe plurality of outlets is a different size than a second outlet of theplurality of outlets.
 6. The pumping system of claim 1, wherein themanifold assembly further comprises a plurality of valves, wherein eachvalve is connected to a respective outlet of the plurality of outlets.7. The pumping system of claim 1, wherein each outlet further comprisesa flange connection on an exterior surface.
 8. The pumping system ofclaim 1, wherein the transition section is either an oval or a circle.9. A method of pumping fluid into a wellbore, the method comprising:flowing the fluid from at least one of a blender or a storage tank to aninlet of a manifold header, the manifold header comprising a manifoldheader body with an interior bore; flowing the fluid into entrancesections of a plurality of outlets fro, the interior bore of themanifold header, each entrance section shaped to have a profile that isapproximately the same as a profile of an inner surface of the interiorbore of the manifold header body; transitioning the fluid from theentrance sections to respective outlet ports of the plurality of outletsvia transition sections of the plurality of outlets, each transitionsection having a radius of curvature that transitions from the profileof the entrance section to the outlet port to reduce internal erosion ofthe outlet due to the fluid flowing from the manifold header and throughthe outlet port, and each outlet port shaped to flow the fluidapproximately perpendicular to a longitudinal axis of the manifoldheader body; distributing the fluid to a plurality of pumping systemsvia the outlet ports; and pumping the fluid into the wellbore via theplurality of pumping systems.
 10. The method of claim 9, whereindistributing the fluid to the plurality of pumping systems via theoutlet ports comprises: distributing the fluid to a first pumping systemof the plurality of pumping systems via a first outlet port of a firstoutlet of the plurality of outlets; distributing the fluid to a secondpumping system of the plurality of pumping systems via a second outletport of a second outlet of the plurality of outlets; and wherein thefirst outlet is a different size than the second outlet.
 11. The methodof claim 9, wherein distributing the fluid to the plurality of pumpingsystems via the outlet ports further comprises opening a valve coupledto an outlet of the plurality of outlets.
 12. The method of claim 9,wherein the fluid is fracturing fluid.
 13. A manifold assemblycomprising a manifold header comprising: a manifold header bodycomprising an inlet to receive the fluid and an interior bore; and aplurality of outlets from the interior bore, each comprising: anentrance section shaped to have a profile that is approximately the sameas a profile of an inner surface of the manifold header body interiorbore; an outlet port shaped to flow the fluid approximatelyperpendicular to a longitudinal axis of the manifold header body; and atransition section shaped to have a radius of curvature that transitionsfrom the profile of the entrance section to the outlet port and reducesinternal erosion of the outlet due to the fluid flowing through theoutlet port.
 14. The manifold assembly of claim 13, wherein the manifoldheader body further comprises holes formed along a length of themanifold header body and each outlet is coupled to the manifold headerbody at a respective hole.
 15. The manifold assembly of claim 13,wherein the outlets are integrally formed with the manifold header body.16. The manifold assembly of claim 13, wherein a surface area of thetransition section between the entrance section and the outlet port isnot uniform about a circumference of the outlet port.
 17. The manifoldassembly of claim 13, wherein a first outlet of the plurality of outletsis a different size than a second outlet of the plurality of outlets.18. The manifold assembly of claim 13, further comprising a plurality ofvalves, wherein each valve is connected to a respective outlet of theplurality of outlets.
 19. The manifold assembly of claim 3, wherein eachoutlet further comprises a flange connection on an exterior surface. 20.The manifold assembly of claim 13, wherein the transition section iseither an oval or a circle.